IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE)

e-ISSN: 2278-1684,p-ISSN: 2320-334X, Volume 12, Issue 5 Ver. IV (Sep. - Oct. 2015), PP 30-37
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Durability and Bonding Characteristics of Plastic Aggregate

Concrete
Anju Ramesan1, Shemy S Babu2 , Aswathy Lal3
1

(P.G. Scholar, Civil Engineering, Sree Buddha College of Engineering, Alappuzha, Kerala, India)
2
(Assistant Director, Kerala Highway Research Institute, Thiruvananthapuram, Kerala, India)
3
(Assistant Professor, Civil Engineering, Sree Buddha College of Engineering, Alappuzha, Kerala, India)

Abstract: This study is intended to explore the durability and bonding characteristics of recycled plastic
aggregate in concrete. Durability of concrete is an important factor. The present investigation focused on the
effects of sulphuric acid, hydrochloric acid and sodium sulphate on the resultant concrete. From the test,
sulphate attack, acid attack and chloride attack on concrete were measured. The obtained results supported the
use of high density polyethylene aggregate for partial replacement of natural aggregate. Bonding of plastic
aggregate in concrete is also an important parameter to be measured. Bonding of plastic aggregate concrete
was tested and studied with the help of pullout apparatus.
Keywords: Acid attack, Bonding, Chloride attack, Durability, Plastic Aggregate, Pullout, Sulphate attack
I. Introduction
Aggregates used in construction are the most mined materials in the world. Modern blasting techniques
increased the number of quarries at places wherever competent bedrock deposits are available. Also construction
demand at places where neither stone, nor sand and gravel are available is usually satisfied by shipping in
aggregate by rail, barge or truck.
Indian construction industry today is amongst the five largest in the world. The demand for new
construction is ever increasing with the rise in population. Hence the need of non-renewable aggregate has
become a challenge. The future seems to be in dark for the construction sector. Researches are being conducted
using alternative for aggregate in the construction field. Focusing on the environment and safeguarding natural
resources, new waste materials have been used in the construction industry. In India, due to growing population
the quantity of solid waste is increasing rapidly. Among the solid waste materials, plastics represent 8% by
weight of the total solid wastes. These non-biodegradable plastic materials will finally end up as earth fill.
For solving the disposal of large amount of plastic materials and to meet the increasing need for
aggregates, reuse of plastic in concrete can be considered as a feasible application. Plastic aggregates will not be
crushed as easily as natural aggregate since plastic are polymers made up of long string molecules consisting of
carbon atoms bonded with other atoms such as hydrogen, nitrogen, oxygen, fluorine. They develop a crystalline
structure which is strong, hard and more resistant to chemical penetration and degradation. Hence it will be a
boon to the construction industry, if plastic can be utilized to prepare aggregates.

II. Plastic Aggregate

After a review of various research studies, high density polyethylene (HDPE) was selected for the
study as a substitute for natural aggregate. HDPE is the largest of the three polyethylenes by volume of
consumption. HDPE is prepared from ethylene by a catalytic process. It is also harder, more opaque and can
withstand higher temperature. They are impact and wear resistant and can have very high elongation before
breaking when compared to other materials. They are resistant to chemical actions and cheaper too. It has a very
linear structure with only a few short side branches and hence leading to higher density range as well as more
crystalline structure. These properties give HDPE its higher strength compared to the other PEs (polyethylene),
allowing a wider range of use. The properties of HDPE are:
Excellent resistance to dilute and concentrated acids, alcohols and bases.
Melting point:130oC - 180oC
Specific Gravity: 0.95
Water absorption: 0.001% - 0.010%
Chemical resistance
Impact and wear resistance
Can withstand high temperature

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Durability and Bonding Characteristics of Plastic Aggregate Concrete

The plastic aggregates were prepared from recycled HDPE sheets. Generally the plastic recycling can
be completed through 5 steps: Sorting, shredding, washing and extruding (Fig 1).

Fig 1 Extruder and Extrusion of Plastic

Plastic sheets of 20mm thick were made out of these recycled materials. Undulations were made on the
surface of the sheets. These sheets were then cut into aggregates of 20mm size (Fig 2).

Fig 2 Plastic Aggregate

III. Objectives
Study (i.e. [1]) revealed that the optimum percentage replacement of natural coarse aggregate using
plastic aggregate was 30%. This study thus compares the properties of natural coarse aggregate concrete with
30% plastic aggregate concrete. Specific objectives of this work include:
To prepare plastic aggregate of 20mm size.
To determine the properties of plastic aggregate
To conduct a comparative study of plastic aggregate and natural aggregate.
To study the durability of mix in which natural aggregate is 30% replaced by plastic aggregate.
To study the bonding characteristics of mix in which 30% natural aggregate is replaced by plastic
aggregate.

IV. Methodology

The successive steps that were followed to complete the study were as follows:
Collection of high density polyethylene (HDPE) materials.
Preparation of recycled plastic aggregate.
Various tests were conducted on cement, fine aggregate, natural aggregate and plastic aggregate to
determine its properties.
Casting of cubes with control mix using natural aggregate.
Casting of cubes for 30 percentage replacement (optimum percentage replacement) of natural aggregate by
plastic aggregate.
Durability against sulphuric acid, hydrochloric acid and sodium sulphate were studied.
The bonding characteristics of the mix were studied.

V. Materials Used
The properties of materials used in the study were determined by conducting necessary test as per IS
specifications and are tabulated subsequently.

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Durability and Bonding Characteristics of Plastic Aggregate Concrete

Table 1 Properties of Cement
Brand

Portland Pozzolana Cement -43 grade; Shankar Cement

Standard Consistency

32%

Initial Setting Time

190 min

Final Setting Time

365 min

Specific Gravity

2.965
43 N/mm2

Mortar Cube Strength

Table 2 Properties of Fine Aggregate

Fineness Modulus

4.129

Zone

Specific Gravity

2.697

Water Absorption

0.2 %

Table 3 Properties of Coarse Aggregate

Fineness Modulus

5.09%

Nominal Size

20 mm

Specific Gravity
Water Absorption

2.745
0.05 %

Table 4 Properties of Plastic Aggregate

Fineness Modulus

5.63

Nominal Size

20 mm

Specific Gravity

0.94

Chemicals like sulphuric acid, hydrochloric acid and sodium sulphate anhydrous were used to carry out
chemical curing. The chemicals were manufactured by NICE Chemicals Pvt. Ltd.

VI. Control Mix

Mix design was performed as per IS: 10262 2009 (i.e. [12]) to obtain M20 mix (TABLE 5). For
making a mix with plastic aggregate, the amount of plastic was calculated using the specific gravity of plastic.
Table 5 Mix Proportion Control Mix
Material
Weight (kg/m3)
Ratio

Cement
383.16
1

VII.

Fine Aggregate
733.584
1.914

Coarse Aggregate
1119.96
2.922

Water
191.58
0.5

Casting Of Specimens

The mix is designated as CM for the control mix and 30P for the mix containing plastic aggregate. A
total of three specimens were casted for each test and the average of the results were considered.
Table 6 Total Specimens Casted
Specimen

Tests Conducted

Dimension

Total Number

Cube

Durability

150 mm x 150 mm x 150 mm

18

Cube

Pullout

150 mm x 150 mm x 150 mm

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Durability and Bonding Characteristics of Plastic Aggregate Concrete

Fig 3 Casting and Curing of Specimens

VIII.

Experimental Procedure

1.1 Determination of Resistance of Concrete to Chemical Attack

Durability of concrete against sulphuric acid, hydrochloric acid and sodium sulphate was checked.
Cubes of 150 mm x 150 mm x 150 mm were casted for CM and for the mix with a replacement of 30% of
natural aggregate by plastic aggregate. The cubes were cured for a period of 7 days. After 7 day water curing,
the specimens were kept in atmosphere for 2 days for constant weight. Subsequently the respective specimens
were weighed and immersed in 2% sulphuric acid solution, hydrochloric acid solution and sodium sulphate
solution respectively for 90 days (Fig 4). After 90 days, the specimens were taken out, washed and kept in
atmosphere for 2 days for constant weight.
The effect of chemical attack was estimated by taking the change of mass into consideration. The
reductions in compressive strength of the specimens when they were immersed in chemical solution were also
determined.

Sulphuric Acid Curing

Hydrochloric Acid Curing

Fig 4 Chemical Curing

Sodium Sulphate Curing

9.2 Determination of Bonding Stress of Concrete

Bonding of the concrete was checked using pullout test. Cube of 150 mm x 150 mm x 150 mm were
casted with a pullout attachment in it. The cylindrical attachment had an inner diameter of 4 cm, outer diameter
of 6 cm and a height of 10 cm (Fig 5).

Cylindrical Attachment
Cube for Pullout Test
Fig 5 Cube Casted with Pullout Attachment

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Durability and Bonding Characteristics of Plastic Aggregate Concrete

IX. Test Results And Discussions
1.2 Sulphuric Acid Attack on Concrete

Fig 6 Pecentage Decrease in Weight of Cubes after H2SO4 Curing

Fig 7 Variation in Compressive Strength of Cubes after H2SO4 Curing

When compared, significant differences in weight losses (Fig 6) were not observed for both the mixes
after 90 days sulphuric acid curing. Mix using plastic aggregate showed more decrease in compressive strength
after H2SO4 curing when compared with control mix using natural aggregate (Fig 7). Sulphate corrodes
aggregate making the concrete surface rough. Sulphate attack was indicated by a characteristic whitish
appearance (Fig 8).

Fig 8 Whitish Appearance on Specimens after Sulphuric Acid Curing

10.2 Hydrochloric Acid Attack on Concrete
Percentage decrese in weight loss (Fig 9) of specimen after 90 days hydrochloric acid curing was
1.46% and 0.5% for CM and 30P respectively.Variation in compressive strength (Fig 10) shows that concrete is
highly resistance to chloride attack on replacement of natural aggregate with plastic aggregate. The strength
differed by 3.1%.

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Durability and Bonding Characteristics of Plastic Aggregate Concrete

Fig 9 Pecentage Decrease in Weight of Cubes after HCl Curing

Fig 10 Variation in Compressive Strength of Cubes after HCl Curing

10.3 Sodium Sulphate Attack on Concrete

Fig 11 Pecentage Decrease in Weight of Cubesafter Na2SO4 Curing

Fig 12 Variation in Compressive Strength of Cube after Na2SO4 Curing

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Durability and Bonding Characteristics of Plastic Aggregate Concrete

When compared, significant differences in weight losses (Fig 11) were not observed for both the mixes
after 90 days sodium sulphate curing. Mix using plastic aggregate showed lesser decrease in compressive
strength after H2SO4 curing when compared with control mix using natural aggregate (Fig 12). Concrete surface
was found to be rough and a white colour appeared on the surface of concrete which indicates sulphate attack
(Fig 13).

Fig 13 Whitish Appearance on Specimens after Sulphuric Acid Curing

10.4 Bonding Stress
The bonding stress of CM was found to be 0.4 N/mm2 and that of 30P was 0.44 N/mm2. This indicates
that the bonding of plastic aggregate is almost the same to that of natural aggregate.

Fig 17 Variation in Bonding Stress

X. Conclusion
A study was conducted to investigate the possibility of making plastic aggregate and using the
aggregate made from plastic as a substitute for natural coarse aggregate in concrete. The present work is aimed
at studying the durability and bonding of concrete with partial replacement of natural aggregate by plastic
aggregate. The study can be concluded as follows:
Plastic aggregate is a lightweight material with specific gravity 0.94.
After 90 days sulphuric acid curing (2% solution), the percentage decrease in weight of the mix containing
plastic aggregate was found to be 1.4% and that of control mix was 1%.
Compressive strength (after sulphuric acid curing) increased by 11% for a mix with 30% replacement of
natural aggregate by plastic aggregate when compared to control mix.
After 90 days hydrochloric acid curing, the percentage decrease in weight of the control mix was 1.46%
whereas that of the mix containing plastic aggregate was 0.5%
After hydrochloric acid curing, there was an improvement in compressive strength by 3% for the mix with
30% plastic aggregate when compared to control mix.
After 90 days sodium sulphate curing (2% solution), the percentage decrease in the weight of the mix
containing plastic aggregate was 1.35% and that of control mix was 1.53%.
Compressive strength increased by 7% for the mix with 30% replacement of natural aggregate by plastic
aggregate when compared to control mix; after sodium sulphate curing.
Results indicated that bonding stress was almost the same for both the mixes. The mix control mix had a
bonding stress of 0.4 N/mm2 whereas the mix containing plastic aggregate had a bonding stress of 0.44
N/mm2
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Durability and Bonding Characteristics of Plastic Aggregate Concrete

Acknowledgment
Apart from the efforts from my side, the success of any project depends largely on the encouragement
and guidelines of many others. I take this opportunity to thank each and everyone who joined me, walked beside
me and helped me in this journey. The guidence and support received from all the members who conttributed
and who are contributing to this project, was vital for the success of the project. I am grateful to their constant
support and help.

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Authors Profile
Anju Ramesan, is pursuing Master degree in Structural Engineering from Sree Buddha College of
Engineering, Kerala, India. She received Bachelor degree in Civil Engineering from Sree
Buddha College of Engineering for Women, Kerala, India.
Email: anjuramesan02@gmail.com

Aswathy Lal, received the degree Master of Technology in Traffic and Transportation Engineering from
College of Engineering, Thiruvananthapuram, India. She is presently working as the Assistant
Professor of Sree Buddha College of Engineering, Kerala, India.

Shemy S. Babu, completed her B.Tech degree in Civil Engineering during 1997 2000. After two years of
experience in the field of teaching, she joined for her post-graduation degree in Structural
Engineering. She presently works for the Kerala Highway Research Institute, Kerala, India as
the Assistant Director. She joined the institute in 2008.

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